Preformed and bonded masonry wall structure



April 21,1959` l J. A. CARLSON FREFoRI/IED AND BoIIpED II/IAsoNRY WALLSTRUCTURE Filed June 16, 1955 G4 es s sheetsu-svheet 1 FIGG` 2' FIG. 7

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INVEN TOR.

JOHN A. CARLSON ATTORNEY FIG.- II

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April 21, 1959 I FREFORMED AND BONDED MASONRY WALL STRUCTURE Filed June16, v1953 J. A. CARLSON 2,882,712

3 Sheets-Sheet 2 JQHN A. CARLSON my ATJQBNEY April 21, 1959 J. A.CARLSON 2,882,712

PREFORMED AND BONDED MASONRY WALL. STRUCTURE Filed June 16, 1955 3Sheets-Sheet 3 fIs.

1N VEN TOR. JOHN A. CARL SON www,

ATTORNEY United PREFORMED AND BONDED MASONRYv WALL STRUCTURE John A.Carlson, MillValley, Calif. Application June 16, 195s, serial No.515,889 4 claims. (ci. 72-16) This invention concerns buildingconstruction of concrete and steel, and more specically provides a newapproach in a combination of precast members and reinforced pouredconcrete.

In the development of this invention, applicant has given specialthought and consideration to achieve a superior and unique constructionfor the purpose of building houses and other types of buildings durableagainst the most destructive elements such as tornado, hurricane,earthquake, and windstorm as well as to provide a shatterproofconstruction to minimize danger to life and damage to property in theevent of enemy attack. Moreover, it is reproof, vermin proof andpermanent in nature, providing a building of maximum strength with onlya minimum of material. With all of these advantages, applicants`invention yet presents a structure competitive in material and erectioncosts with standard types of frame building construction of equivalentsize. Furthermore, being fully insulated, it produces a constructionthat is cool for hot climates and warm in cold climates and absolutelyproof against outside moisture.

This construction provides walls of precast reinforced concrete vmembersand reinforced poured concrete. The precast members` are simple to formand are easily and quickly assembled resulting in a sound bonded andpractical wall. construction. The members are interlocked withspecial-ly designed metal rods and fixtures and are then securely bondedtogether horizontally by embedding their bases in footings and by'poured reinforced concrete girders along the top of the wall.

Pilasters are obtained by pouring concrete into prearranged molds formedmostly of the precast members themselves. Such pilasters may be formedat intervals from corner to corner or to points adjacent the Ajoinder ofa partition wall and an outside wall.

Furthermore, by the setting of the panel slabs in their proper positionin the wall, back to back and lateral side edges to lateral side edges,there will be provided forms or molds where the four panel slabs abut.This mold when lled with concrete results in a concrete bonding stud,locking and bonding vertically all `four members at that juncture.

The provision of such precast members, xtures and rods referred toabove, together with their assembly into a wall construction, as well asthe resultant wall, constitutes the principal object of this invention.

Additional objects and advantages of this invention will become moreapparent as the following description proceeds when taken in conjunctionwith the accompanying drawings, in which:

Fig. 1 is an elevational View of the inner surface of a panel slab.

Fig. 2' is a top end view of Fig. l.

Fig. 3 is a bottom end view of Fig. 1.

Fig. 4 is a vertical cross sectional view of an exterior wall prior tocompletion with poured concrete.

Fig. 5 is a vertical cross-sectional view of an interior '2,882,712PatenteclApr. 2l, 1.9.59

2 partition wallv prior to its completion with poured concrete.

Fig. 6 is a slightly enlarged partial vertical section taken on line 6 6of Fig. 1.

Fig. 7 is an elevational View illustrating the surface side of a panelslab, the reverse or inner side being illustrated in Fig'. 1.

Fig. 8 is a slightly enlarged cross section on lines 8 8 of'Fig; l.

Figs. 9 and l0 illustrate in horizontal cross section, an exterior walland an interior partition wall respectively.

Fig. ll is a vertical view longitudinally and centrally of a Wall,takenk on line 11-11 in Fig. 4.

Fig. l2 is an enlargement of Fig. 9.

Fig. 13 is a side elevation of aclamping fixture arrangement.

Fig. 14 is an end View of Fig 1-3.

Fig. 15 is an end View of' a girder forming member and cover.

Fig. 16 is a perspective view illustrating concrete panel slabs inposition embedded in footings and top girders after concrete has beenpoured and' forms removed resulting in. an exterior wall.

Fig.. 17 is a perspective view illustrating concrete panel slabs inposition embedded in footings and top girders after concrete has beenpoured and forms removed resulting in an interior partition wall.

Fig. 18 is a side elevation of a wall taken in the center of the wallafter the concrete has been poured and'rnore clearly shows the topconcrete girder, bonding studs, pilasters and footing constructionaccording to this invention.

Fig. 19 is a horizontal cross section of an exterior wall corner.

Fig. 20 is an enlarged horizontal cross section of; an interiorpartition wall at the level of the reinforcing ribs.

Fig. 2l is an enlarged horizontal cross section view of an exterior wallshowing insulation and concrete bonding studs.

Fig. 22 is a horizontal cross sectional view showing a partition walljoining an exterior Wall.

Fig. 23 is a top view illustrating forms and methods of providingnecessaryv variation take-up joints for an interior partitionwall.

Fig. 24 is a top view similar to Fig. 23 but for the exteriory walls.

Referring now more particularly to the drawings, in Figs. 1, 2, 3, 6, 7and 8 there is illustrated precast concrete panel slabs 15 and 40. Thesurfaces 16 on both are smooth, or may be slightly roughened if desiredfor finishing With stucco or plaster for its better adherence. It shouldbe stated here that panel slabs 15 and 4t) in design and with respect tothe molded detail on their rear or inner surfaces are the same. Panelslabs 15 are used on the interior side of an outer wall, and are alsoused back to back in interior partition walls.

Panel slabs 40 with the same molded detail are cast in a mold or form,the bottom of which, has been designed for the insertion of furringstrips 41 and 42. These furring strips are laid in their respectivepositions in the form or mold. Reinforcing wire is provided on thesurface of the furring strips 41 and 42 over which the concrete ispoured, so that the furring strips adhere to the panel slabs after theircasting has been completed. These furring strips 41 and 42 facilitatethe fastening to themthe panel slabs as the wall is erected. After theinsulation material has been attached the panel slabs 40 are ready forthe exterior side of an exterior wall.

The top edges 21 `of both types of panel slabs 15 and 40, as shown inFig. 6 are beveled upwardly from the front surface 16 toward the rear toform a dovetail joint to lock the tops of the panel slabs into thepoured concrete top girder. The tops of the panel slabs 15 and 40 arevalso reduced in width providing notched corners 23 and 25, the purposefor which will be explained later.

As stated previously, the front surfaces 16 of panel slabs 15 and 40 aregenerally smooth but may be roughened if desired to better adhere stuccoor other finishes. The rear sides 17 however are provided withintegrally formed cross ribs 28, 29 and 30 which extend horizontallyacross the panel slabs at the top, center and bottom. The sides areprovided with longitudinal ribs 27. All of these ribs are spacedinwardly from the edges of the panel slabs providing a margin 19. Theouter edges of the lateral ribs 27 are formed in the shape of a V 24(see Fig. 8) and the upper edge 22 of the top cross ribs 29 slopedownwardly and inwardly toward the front surface 17 of the slab.

Near the base of and crossways of the panel slabs 15 and 40, is a moldedgroove 33. When the panels are set ush back to back for an interiorpartition wall, the grooves 33 together provide a hole for tie rods. Thebase of the panel slabs 15 and 40 are also reduced in width a shown at32.

In Fig. 4 there is illustrated the position in an outer Wall of panelslabs 15 and 40 relative to footing forms. It also shows the top girderforms in position. The footing forms 50 comprise parallel retainingmembers 51 and 52 which may consist of planking, steel channels or thelike, uniformly spaced apart by means for a separator tube or pipe 53.The relative positions of the retaining members 51 and 52 are securelymaintained by a tie rod 54 extending through the tube 53 and bores inthe retaining members 51 and 52, after nuts 55 on either side have beentightened. To facilitate the tightening of the members 51 and 52 if madeof wood, suitable inner and outer washers are employed between the tubesor pipes 53 and the planking 51 and 52 and between the planking and thenuts 55.

Paralleling and spaced from one of the retaining members 51 for example,an angle iron 57 is secured, preferably by welding, to the tubes orpipes 53. Another angle iron 58 rests on the tubes or pipes 53 andparallels the angle iron 57 but is not secured, so that its position maybe adjusted relative to the lixed angle iron 57. This adjustment isaccomplished by cross bolts 92 which extend through bores previouslydrilled in the angle irons and spaced to coincide with openings providedby the reduced bottom ends 32 -of the panel slabs 15 and 40.

The remaining members will be best described in the discussion of theprocedure for erecting a section of a wall incorporating a number ofpanels slabs 15 and 40 in pairs, back to back, and said pairs arrangedside by side, panel slabs 40 for the exterior of an outside wall andpanel slabs 15 for the interior surface of the exterior wall.

Two panel slabs 15 and 40 are placed back to back between the channellike angle irons 57 and 58 and intermediate a pair of cross tie bolts 92which, after the panel slabs have been plumbed true, are tightened tosecurely hold them between the angle irons. To these erected panel slabsanother pair of panel slabs 15 and 40 are placed side by side, thesquare edges 20 of each abutting together. Their reduced bases 32 arepositioned between the next pair of cross tie bolts 92 which are put inplace and tightened.

At this time a tie rod 75 (see Fig. 11) threaded on either end, isplaced centrally within the wall between panel slabs 15 and 40. This tierod is approximately 3A of an inch shorter than the width of the panelslabs and is anchored to .the next adjacent pair of panel slabs.

An anchor bar 73 in Ithe form of a channel and provided with a centrallylocated bore is fitted over the free threaded end of the bar 75 in arelatively horizontal posi tion within the reduced upper corners 23 ofthe panel slabs. This bar 73 is in length slightly less than thethickness of the wall and bears against the reduced portions 23 of thepanel slabs after a sleeve nut 74 has been threaded onto the tie bar 75.In this manner, adjacent pairs of panel slabs are drawn tightlytogether. This procedure continues in repeated sequence top and bottomuntil :a wall between at least two pilasters has been erected. It shouldbe noted that the anchor bars 76 along the bottom of the wall arepositioned within and bear against the reduced portions of the panelslabs. These lower bars 76 may be in length greater than the thicknessof the wall to better cross brace the walls by engaging the concrete ofthe poured footings.

It should be now noted that as soon as two pairs of panel slabs havebeen erected and mechanically secured together as described above, thereis provided within the juncture a self contained mold or form into whichmay be poured a concrete bonding stud 60 (see Fig. 9 or 21). Such a studproperly reinforced, concrete lock-bonds Athe pairs of slabs verticallyin place in the wall.

For erecting partition walls, the method already described for exteriorwalls is repeated, the only difference between an exterior wall and apartition wall being that Ea partition wall is made entirely of panelslabs 15, no insulation material being required in between. The width ofthe footings, the wall itself, and the top girder therefore are slightlyless than in exterior walls.

After all the walls, or a reasonable length of wall section, or a wallsection between two pilasters has been erected as discussed above, athin steel angle iron 72 or 81 (see Figs. 4 and 5) may be placed overthe two sloping upper horizontal ribs 22 of the panel slabs 1S and 40for an exterior wall, and the panel slabs 15 in a partition wall. Thissheet metal angle or angle iron in length extends only between onebonding stud 60 and another in the exterior wall, and from one bondingstud 61 to another bonding stud 61 in a partition wall, thus permittingthe poured concrete in the bonding studs and pilasters to form amonolithic bond with the concrete poured above the angles 72 and 81 toform a continuous concrete top girder. These angle irons or sheet steelangles act as a cover preventing water from the wet concrete fromrunning down between the various panel slabs, and in the case of theexterior wall, this cover protects the insulation material from becomingwater soaked. In certain instances, the angle steel cover may beomitted, particularly where no insulation is involved.

Continuous top wall girders 62 and 63 (see Figs. 16, 17 and 18) areformed in part utilizing a form structure similar to that described inconnection with the footing forms 50. As illustrated in Fig. 4, members64 and 65 for exterior wall construction are drawn together against theface surfaces of the upper ends of panel slabs 15 and 40 and against aspacing ferrule or tube 68 by means of a tie rod 69 extending throughholes bored in the form members 64 and 65 and the ferrules or tubes 68.Suitable washers and nuts secure the forms in the same manner asdescribed with reference to the setting up of the footing forms 50. Thespacing ferrules or tubes 68 rest on the top edges 25 and in the reducedupper corners 23 of the panel slabs 15 and 40.

Steel reinforcing, not shown, is incorporated into the top girder to bepoured according to accepted strength standards.

This procedure of supplying girder forms for the top of the exteriorwall, is repeated in every detail with re spect to forms for the topgirder of the partition walls, the thickness of the partition wallgirder being somewhat less.

After the top and bottom forms are thus in place and a nal check is madeto insure that the various panel slabs are plumb, concrete Vis thenpoured`in the footing forms, the forms provided by the juncture of pairsof panel slabs themselves, and the top girder forms. All the tie rods 75and anchor ybars 73 and 76 are thereby submerged and embedded vin theconcrete both top and bottom, adding additional reinforcing materialthereto and assuring the lock-bonding of the precast members and 40,resulting ina continuous solid monolithic construction.

The height of the walls can be varied somewhat by the height of the topgirder forms used.

Figs. 9 and l0 illustrate the difference in the horizontal cross sectionof exterior walls and interior partition walls. Fig. 9 also shows theair spaces 43, provided by the molded shape of the inner or back sidesof panels 15 and 40. This air space extends from cross ribs 29'to thecenter rib 28, down to the base 30, thus adding greatly to theinsulation value of the' wall, because these air spaces 43 are on bothsides ofthe insulation material 45 near the center of the wall.

in the slightly enlarged showing of Fig. 12 there is illustrated inaddition to the central insulation material 45, insulation material 46between joints of panel slabs 15 and the concrete bonding stud 6.0.

Fig. 16 in perspective illustrates the panel slabs in position after thefootings-and top girder have been poured and the forms removed,comprising a section of exterior wall construction. It shows withclarity the purpose of the angle iron 72 which covers the center jointsbetween the two panel slabs, and forms the bottom of the top girder. Italso shows the purpose for the top beveled or sloped ends 21 and 25 ofthe panel slabs to more securely bond top edges of panelslabs 1'5 and 40with the top concrete girder, in ay dovetail manner. It furtherillustrates the finished footings,vand shows how lthoroughly the basesof the panel slabs 15 and 40v have been ernbedded in the footings.

Fig. 17 illustrates the same general principle of concrete footing andtop girders, in fact identical to Fig. 16 excepting that it illustratesa partition wall section.

Fig. 18 more clearly shows the reinformed concrete girder, pilaster,bonding studs and footing type of construction in connection with panelslabs.

Fig. 19 shows a corner pilaster, in relation to two exterior wallsections, and also illustrates corner plank forms to complete the cornermold or form, which when filled with concrete lock-bonds the twoadjoining wall sections together.

Fig. 20 shows the proper positions of the partition wall panel slabs 15back to back, with all four lateral edges butting together, providingthe self contained form which when filled with concrete lock-bonds thesepanel slabs with a concrete bonding stud 16.

Fig. 22 illustrates a part of two exterior wall sections, adjoining aninterior partition wall. It also shows a steel plate 102 which, with twoexterior wall sections and the interior partition section completes amold or form for the making of an exterior wall partition pilaster whenpoured with concrete.

Figs. 23 and 24 illustrate a method for attending to any variation thatmay arise in the walls between two given points. This is taken care ofby the placing of a steel form plate on either side of the wall andfilling the resultant space with concrete 87 and 86. It will be noted inthese two Figures 23 and 24 that when the concrete has filled this moldor form, it too will lock-bond the adjoining ends of the panel slabsinto a solid monolithic concrete construction.

It will be understood that applicants invention resides in the novelcombination and cooperation of various members together with theirassembly and the method of bonding them in poured concrete, for the mostpart in forms furnished by the precast members themselves, and thatcertain modifications in the arrangements illustrated will be suggestedto those skilled in the art. All

such modifications vas come within its spirit are intended prisingprecast members each in the form of elongate concrete panel slabsextending vertically the height of an entire story, each of said panelslabs having a face surface and an inner surface, the inner surfacesbeing provided with longitudinal and cross ribs, the longitudinal ribsat least being spaced inwardly from the lateral edges of the innersurfaces thereby defining inner surface marginal portions, said lowermarginal portions being relieved, footing form cross supports, aretaining piece running transverse and fixed to said cross supports, asecond retaining piece running parallel to the said fixed retainingpiece and adjustably spaced from the fixed retaining piece, a pluralityof pairs of said panel slabs each pair positioned with their ribbedinner surfaces facing one another, adjacent pairs arranged with theirlateral sides in contact, the lower ends of said plurality of pairs ofpanel slabs extending between said retaining pieces, threaded rods andnuts extending between the retaining pieces through said lower relievedmarginal portions for securing the lower ends of said plurality of pairsof panel slabs therebetween, means extending horizontally lengthwise ofthe wall for mechanically securing adjacent pairs of said panel slabs inabutting side by side relationship comprising anchor bars extendingcrosswise of the pairs of panel slabs and bearing against said relievedlower marginal portions thereof, and threaded tie rods and sleeve nutsextending horizontally lengthwiseV of the wall between said anchor barsfor mechanically securingV said pairs of panel slabs inV abutting sideby side relationship, the upper surfaces of the upper' cross ribs ofsaidpanel slabssloping downwardly toward the inner surfaces of the panelslabs providing an angular. bottom for top girder forms, notches in theupper corners of said panel slabs, top girder form cross supportsresting in the notches in the upper corners of the panel slabs forreceiving top girder forms along the upper portion of the face sides ofsaid panel slabs and extending above the top edges thereof, and pouredconcrete footings embedding the bases of all of said panel slabs atleast to the height of said relieved lower marginal portions thereof,the footing form cross supports, retaining pieces, the anchor bars, tierods and sleeve nuts poured concrete filling the vertical spaces betweenlaterally abutting pairs of said panel slabs, said spaces being definedby said inner surface marginal portions and said longitudinal ribs, and.poured concrete filling the spaces above the sloping surfaces of the topribs of the panel slabs embedding the top girder cross supports formingat least in part a top girder further bonding together said precastpanel slabs due to angular girder bottom formed by the sloping uppersurfaces of the upper cross ribs of the panel slabs, all of said pouredconcrete lock bonding adjacent precast members together with allmechanical securing and retaining means into a unitary assembly.

2. A wall construction as claimed in claim l, including insulationmaterial disposed between the pairs of panel slabs and in which the topedges of the panel slabs are beveled downwardly and outwardly, and anangle shaped steel member conforming substantially to the angle of thebevels of the top surfaces of the upper ribs interposed between the topsurfaces of said upper ribs and the poured concrete top girder, foradding further reinforcing steel within the top girder of the wall andfor capping the insulation material interposed between the pairs ofpanel slabs, preventing the wet poured concrete of the top girder fromdamaging the insulation material prior to its setting.

3. A wall construction as claimed in claim 1, in which the upper edgesof said panel slabs are also beveled downwardly and outwardly towardsaid outer surfaces to form dovetailed joints with concrete pouredthereover for a top girder and in which the lower ends of said panelslabs are reduced in width to the extent eliminating said inner marginalportions and adapted to be inserted at least to the extent of saidportion of reduced width into the poured concrete footings.

4. A wall construction for buildings including a monolithic framework ofconcrete reinforced with steel, comprising precast members each in theform of elongate concrete panel slabs extending vertically the height ofan entire story, each of said panel slabs having a face surface and aninner surface, the inner surfaces being provided with longitudinal andcross ribs, the longitudinal ribs at least being spaced inwardly fromthe lateral edges of the inner surfaces thereby defining inner surfaceAmarginal portions, said lower marginal portions being relieved, footingform cross supports, a retaining piece running transverse and fixed tosaid cross supports, a second retaining piece running parallel to thesaid fixed retaining piece and adjustably spaced from the xed retainingpiece, a plurality of pairs of said panel slabs each pair positionedwith their ribbed inner surfaces facing one another, adjacent pairsarranged with their lateral sides in contact, the lower ends of saidplurality of pairs of panel slabs extending between said retainingpieces, securing means comprising anchor bars extending crosswise of thepairs of panel slabs and bearing against relieved marginal portionsthereof and tie rods extending horizontally lengthwise of the wallbetween the anchor bars and in a plane extending vertically between thesaid retaining pieces for mechanically securing said pairs of panelslabs in abutting side by side relationship, the upper surfaces of theupper cross ribs of said panel slabs sloping downwardly toward the innersurfaces of the panel slabs providing an angular bottom for topgirder'forms, said upper marginal portions being relieved in the vformof notches in the upper corners of said panel slabs, top girder formcross supports resting in said notches in the upper corners of the panelslabs for receiving top girder forms along the upper portion of the facesides of said panel slabs and extending above the top edges thereof, andpoured concrete footings ernbedding the bases of all of said panel slabsat least to the height of said relieved lower marginal portions thereof,the footing form cross supports and retaining pieces, poured concretefilling the Vertical spaces between laterally abutting pairs of saidpanel slabs, said spaces being defined by said inner surface marginalportions and said longitudinal ribs, and poured concrete filling thespaces above the sloping surfaces of the top ribs of the panel slabsembedding the top girder form cross supports forming at least in part atop girder further bonding together said precast panel slabs due toangular girder bottom formed by the sloping upper surfaces of the uppercross ribs of the panel slabs, all of said poured concrete lock bondingadjacent precast members together with all mechanical securing andretaining means into a unitary assembly.

References Cited in the file of this patent UNITED STATES PATENTS1,702,659 Mixes Feb. 19, 1929 1,863,981 Groves June 2l, 1932 1,889,699Ranck Nov. 29, 1932 1,892,605 y Betzlel` Dec. 27, 1932 FOREIGN PATENTS521,194 France July 7, 1921 618,586 Great Britain Feb. 24, 1949 802,713Germany Feb. 22, 1951 1,046,177 France June 8, 1953

